Fluid storage tank assembly

ABSTRACT

A fluid storage tank assembly comprising a wall assembly, a floor assembly and a roof assembly. The wall assembly providing a thermal insulating layer comprising two or more wall sub-assemblies removably stacked on top of each other that circumscribe an interior chamber of the tank assembly. Each wall sub-assembly comprises a plurality of removably interconnected wall panels circumscribing a portion of the interior chamber. The wall assembly is configured to house a liner for containing a fluid. The floor assembly bounds a bottom portion of the interior chamber and provides a thermal insulating layer. The roof assembly bounds a top portion of the interior chamber and provides a thermal insulating layer.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to Canadian Application Number______ filed Nov. 16, 2011, by the Canadian firm Gowling, Lafleur, Henderson LLP, under attorney docket number A8124182CA, which is hereby incorporated by reference.

FIELD

The present disclosure relates to a fluid storage tank assembly.

BACKGROUND

Fluid fracturing processes in oil and gas completion operations make use of large quantities of fluid typically stored in large fluid storage tanks located in close proximity to a wellbore. The tanks are typically assembled on a site on a temporary basis and then removed when use of the tank at the site is not longer required. Depending on the jurisdiction in which the tank is located, the size of the tank and the effective storage capacity of tank may be limited by local regulations, bylaws, licensing requirements, and other restrictions respecting the surface area covered by the tank, the permitted water levels in the tank for the protection of wildlife, the maximum load sizes that may be transported on public roads, and other factors. Some prior art storage tank designs are unable to provide adequate storage capacity while complying with such restrictions.

Further, the fluid contained within the storage tank is typically maintained within specific temperature ranges suitable for the fracturing process through the use of heating systems. The cost of heating the fluid can be extremely high, especially in cold environments. Some prior art storage tank designs do not provide adequate insulation to effectively reduce heat loss from the tank, thus, resulting in significant heating costs.

SUMMARY

According to one aspect of the present disclosure, there is provided a fluid storage tank assembly comprising:

-   -   a wall assembly circumscribing an interior chamber of the tank         assembly and providing a thermal insulating layer, the wall         assembly comprising two or more wall sub-assemblies removably         stacked on top of each other, each wall sub-assembly comprising         a plurality of removably interconnected wall panels         circumscribing a portion of the interior chamber, the wall         assembly configured to house a liner for containing a fluid;     -   a floor assembly bounding a bottom portion of the interior         chamber and providing a thermal insulating layer; and     -   a roof assembly bounding a top portion of the interior chamber         and providing a thermal insulating layer.

The floor assembly may comprise a surface gradient operable to direct fluids contained in the tank assembly to a desired location on the floor assembly. The floor assembly may comprise a plurality of floor panels and an insulating layer fixed to the floor panels and shaped to provide the surface gradient. The plurality of floor panels may comprise an arrangement of parallel substantially rectangular panels configured to bound the bottom of the interior of the wall assembly, each panel extending across the interior of the wall assembly and having ends shaped to substantially conform with the interior boundary of the wall assembly. Alternatively, the plurality of floor panels may comprise an arrangement of substantially rectangular panels configured to bound the bottom of the interior of the wall assembly wherein panels located adjacent to the interior boundary of the wall assembly shaped to substantially conform with the interior boundary of the wall assembly. A portion of the floor panels near the desired location on the floor assembly may not comprise a thermal insulating layer. The insulating layer may comprise a channel therein configured to receive a suction pipe near the boundary of the interior of the wall assembly and direct the suction pipe to the desired location on the floor assembly. Each floor panel may be removably coupled to adjacent floor panels. The floor panels may comprise plywood and the insulating layer may comprise foam insulation.

Each wall panel may further comprise an insulating layer fixed thereto. The insulating layer may comprise a spray foam applied to the exterior surface of each wall panel. Each wall panel may comprise a plurality of male connectors at one end and a plurality of female connectors at an opposite end, the male connectors configured to be received by and removably coupled to the female connectors of an adjacent wall panel in a wall sub-assembly, the female connectors configured to received by and removably coupled to the male connectors of an adjacent wall panel in the wall sub-assembly. The wall assembly may further comprise a plurality of joint pins and locking bars, each male connector may comprise one or more apertures configured to receive a joint pin therethrough, each female connector may comprise one or more apertures configured to receive a joint pin therethrough, each female connector further comprises a plurality of gussets extending from an exterior surface of the female connector and shouldering one of the apertures therein, each gussets comprising an aperture configured to receive a locking bar therethrough, the apertures of the male connectors and female connectors may be configured to be in alignment with one another to receive a joint pin therethrough when the male connectors are received by the female connectors, and each locking bar may be operable to be received by the apertures of the gussets of a female connector and interact with a joint pin received by a female connector and a male connector received by the female connector to resist the withdrawal of the joint pin therefrom. Each wall sub-assembly may be removably coupled to an adjacent stacked wall sub-assembly by a cooperating tongue and groove assembly. The wall panel of at least one of the removably coupled wall sub-assemblies may comprise a bottom stiffener fixed to the wall panel at its bottom edge and running parallel thereto, the bottom stiffener and the portion of wall panel near its bottom edge defining the tongue of the tongue and groove assembly, and the wall panel of at least the other of the removably coupled wall sub-assemblies may comprise a top stiffener fixed to the wall panel an offset distance below its top edge and running parallel thereto and a guide plate fixed to the top stiffener and extending vertically therefrom, the top stiffener, the guide plate and the portion of the wall panel within the offset distance defining the groove of the tongue and groove assembly. Each wall panel may further comprise a plurality of stiffeners coupled thereto for providing additional structural support to the wall panel.

The roof assembly may further comprise a plurality of flexible roof segments and a fastening assembly, the fastening assembly operable to couple adjacent roof segments to one another. The roof assembly further may comprise a support pole assembly comprising one or more poles extending from the bottom of the tank assembly above the top of the wall assembly, the support pole assembly at least partially supporting the roof segments. The roof assembly may further comprise a drainage assembly comprising a plurality of apertures through the roof segments located at low points on the roof segment formed by a natural sag of the roof segments between the support pole assembly and the top of the wall assembly. Each roof segment may comprise a top portion and a skirt portion, the top portion configured to substantially cover the top of the wall assembly, and the skirt portion configured to extend down a portion of the exterior surface of the wall assembly. The skirt portion of each roof segment may be removably coupled to the wall assembly. The roof assembly may further comprise a lifting assembly fixed to the roof segments providing a point of attachment for positioning and orienting the roof segments. The lifting assembly may comprise one or more of Velcro straps and safety buckles. The roof segments may comprise vinyl with a water resistant coating. The drainage assembly may further comprise a mesh layer over each aperture in the roof segments.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 provides a front perspective view of a modular fluid storage tank assembly according to one embodiment.

FIG. 2 provides a front perspective view and detailed views of the wall assembly of the tank shown in FIG. 1.

FIGS. 3 and 4 provide front perspective views and detailed views of the upper wall sub-assembly of the wall assembly shown in FIG. 2.

FIGS. 5 and 6 provide front perspective views and detailed views of the lower wall sub-assembly of the wall assembly shown in FIG. 2.

FIG. 7 provides a side elevation view and front perspective view of a joint pin of the wall assembly shown in FIG. 2.

FIG. 8 provides a side elevation view and front perspective view of a locking bar of the wall assembly shown in FIG. 2.

FIG. 9 provides a front perspective view of the coupling of two adjacent wall panels as shown in FIGS. 3 and 4 with the joint pin shown in FIG. 7 and the locking bar shown in FIG. 8.

FIG. 10 provides a plan view and front elevation view of the floor assembly of the tank shown in FIG. 1.

FIGS. 11A to 11C provide a front perspective view and cross-sectional views of the roof assembly of the tank shown in FIG. 1.

FIG. 12 provides a flow diagram of a method of assembling the tank shown in FIG. 1A according to one embodiment.

DETAILED DESCRIPTION

The embodiments of the present disclosure relate to a modular fluid storage tank assembly and a method of assembling the same. The fluid storage tank assembly comprises a modular design that facilitates the efficient transportation and the rapid assembly and disassembly of the tank. Further, the fluid storage tank assembly is designed to reduce heat loss from fluids contained in the tank.

Referring to FIGS. 1A and 1B, a fluid storage tank assembly 10 according to one embodiment is shown generally comprising a wall assembly 20, a roof assembly 30, a floor assembly 40, and a liner 50.

Wall Assembly

Referring to FIG. 2, the wall assembly 20 generally comprises an upper wall sub-assembly 210, a lower wall sub-assembly 250, joint pins 300, locking bars 320, wall braces 340, and clamp assemblies 360. The components of the wall assembly 20 are generally manufactured from steel plate of suitable grade and thickness. Alternatively, the wall assembly 20 may be manufactured from any suitable material. Further, while the wall assembly 20 is depicted in the present embodiment as comprises upper and lower wall sub-assemblies, it sis to be understood that the wall assembly may comprises three or more wall sub-assemblies stacked on top of one another.

The upper wall sub-assembly 210 generally comprises a plurality of interconnected upper wall panels 212 forming an upper hollow cylindrical enclosure. Similarly, the lower wall sub-assembly 250 generally comprises a plurality of interconnected lower wall panels 252 forming a lower hollow cylindrical enclosure. The upper wall sub-assembly 210 is positioned on top of and in axial alignment with the lower wall sub-assembly 250 forming an extended hollow cylindrical enclosure configured to retain the liner 50 within its interior. In the alternative, the wall assembly 20 may be configured to form other continuous circumferential enclosures, such as, for example, a hollow polygonal cylindrical enclosure.

Referring to FIGS. 3 and 4, each upper wall panel 212 generally comprises a wall plate 214, stiffeners 215, clamp mounts 222, female connectors 225, male connectors 236, stacking components 237, and an insulating layer 245.

The wall plate 214 comprises a curved rectangular plate having a curvature such that the assembly of a plurality of upper wall plates 214 forms a continuous hollow circular cylindrical enclosure. Alternatively, the wall plate 214 may comprise a planar rectangular plate or other form of plate such that the assembly of a plurality of upper wall plates 214 forms a continuous circumferential enclosures, such as, for example, a hollow polygonal cylindrical enclosure.

Stiffeners 215 are fixed to the wall plate 214 to provide structural support, as well as, provide elements that can be used for the positioning and orientation of the wall panel 212 during assembly and disassembly of the tank 10. The stiffeners 215 generally comprise a top stiffener 216, vertical stiffeners 218, a bottom stiffener 220, and lifting lug stiffeners 224. The top stiffener 216 comprises an elongate “L” shaped beam fixed to the wall plate 214 near its top edge and running parallel thereto from one end to the other end of the wall plate 214. The vertical stiffeners 218 comprise elongate rectangular plates fixed at one or more locations along the length of the wall plate 214 and running from the bottom to the top of the wall plate 214. The bottom stiffener 220 comprises elongate rectangular tube fixed to the wall plate 214 at its bottom edge and running parallel thereto from one end to the other end of the wall plate 214. Lifting lug stiffeners 224 comprises rectangular plates fixed to the vertical stiffeners 218 and top stiffener 216 where an aperture is provided through the lifting lug stiffener 224 and the vertical stiffener 218 or top stiffener 216. The apertures serve as attachment points for hooks or other devices for the positioning and orientation of the upper wall panel 212 during assembly and disassembly of the tank 10. Alternatively, the stiffeners 215 may comprise more or less vertical, horizontal or other stiffeners for providing structural support, as well as, elements that can be used for the positioning and orientation of upper wall panels 212 during assembly and disassembly of the tank 10.

Female connectors 225 generally comprise a female backbone 226, female inside plates 228, female outside plates 230, and locking bar gussets 234, 236. The female backbone 226 comprises a generally rectangular plate fixed to one longitudinal end of the wall plate 214 running from the bottom to the top of the wall plate 214. The female backbone 226 has a thickness selected to permit the male connectors 236 to be received by the female connectors 225. Alternatively, the wall plate 214 may serve as the female backbone 226. The female inside plates 228 comprise generally rectangular plates that are fixed to the inner surface of the female backbone 226 spaced along the length of the female backbone 226, and extend away from the wall plate 214 in a direction parallel to the length thereof Similarly, the female outside plates 230 comprise generally rectangular plates that are fixed to the outer surface of the female backbone 226 spaced along the length of the female backbone 226, and extend away from the wall plate 214 in a direction parallel to the length thereof. Each female outside plate 230 is positioned on the outside surface of the female backbone 226 so as to oppose and pair with a corresponding female inside plate 228 fixed to the inside surface of the female backbone 226. In addition, each female outside plate 230 and paired female inside plate 228 comprise a set of apertures 229, 231 in alignment with one another that are configured to receive a joint pin 300 (as further described below). Each female connector 225 also comprises locking bar gussets 232, 234 fixed to the outside surface of the female outside plate 230 shouldering one of the apertures 231 in vertical alignment with one another. The locking bar gussets 232, 234 comprise apertures 241 that are aligned with apertures 241 in adjacent locking bar gussets 232, 234 that are configured to receive a locking bar 320. As further described below, the aperture 241 of locking bar gusset 234 comprises an open-ended aperture that extends to the top edge of the gusset 234 such that the handle 324 of the locking bar 320 can pass through the aperture 241 as the bar 322 of the locking bar 320 is inserted through the apertures 241 of the locking bar gussets 232, 234. For the purpose of this disclosure, each female inside plate 228, corresponding female outside plate 230, the portion of the female backbone 226 therebetween, and locking bar gussets 234, 236, will be referred to as a single female connector 225.

Male connectors 236 comprise generally rectangular plates that are fixed to the longitudinal end of the wall plate 214 opposite to the longitudinal end to which the female connectors 225 are fixed, and extending away from the wall plate 214 in a direction parallel to the length thereof Male connectors 236 are spaced along the length of the end of the wall plate 214 such that for each female connector 225 fixed to the opposite end of the wall plate 214 there is a corresponding male connector 236 in vertical alignment therewith. Each male connector 236 also comprises a set of apertures 237 configured to be in alignment with apertures 229, 231 of a corresponding female connector 225 of an adjacent upper wall panel 212 when received thereby. In this manner, when the male connectors 236 of one upper wall panel 212 are received by the female connectors 225 of another upper wall panel 212, the apertures 229, 231 of each female connector 225 and the apertures 237 of each received male connector 236 will be in alignment such that they are capable of receiving a joint pin 300 therethrough.

Stacking components 237 facilitate the stacking of upper wall panels 212 upon one another during transportation or storage. In addition, the stacking components 237 function to protect the insulating layer 245 of the upper wall panels 245 from damage that may be otherwise cause by adjacent stacked upper wall panels 212. Stacking components 237 generally comprise stack up gussets 238 fixed near the longitudinal ends of the top stiffener 216 and extending in a generally perpendicular direction outwardly from the outer surface of the wall plate 214, and stack up stand offs 240 fixed near the longitudinal ends of the bottom stiffener 220 and extending in a generally perpendicular direction outwardly from the outer surface of the wall plate 214. In the alternative, other stacking components suitable for facilitating the stacking of upper wall panels 212 may be employed.

Clamp mounts 222 comprise generally “I” shaped mounting brackets fixed to the outer surface of the wall plate 214 for mounting clamp assemblies 360. As further described below, the clamp assemblies 360 are mounted to the clamp mounts 222 and clamped to the liner 50 to couple the liner 50 to the wall assembly 20. Alternatively, other clamp mount 222 configurations suitable for mounting a clamp assembly 360 may be used.

An insulating layer 245 is coupled to the outside surface of the wall plate 214. The insulating layer 245 may be comprised of suitable spray foam applied to the outer surface of the wall plate 214. Alternatively, the insulating layer 245 may be coupled to the inner surface of the wall plate 214. In the further alternative, the insulating layer 245 may comprise insulating panels or other insulating materials coupled to the outer and/or inner surface of the wall plate 214.

Referring to FIGS. 5 and 6, each lower wall panel 252 generally comprises a wall plate 254, stiffeners 253, guide plates 266, female connectors 267, male connectors 282, and stacking components 283.

The wall plate 254 comprises a curved rectangular plate having a curvature such that the assembly of a plurality of lower wall plates 254 forms a continuous hollow circular cylindrical enclosure. Alternatively, the wall plate 254 may comprise a planar rectangular plate or other form of plate such that the assembly of a plurality of lower wall plates 254 forms a continuous circumferential enclosures, such as, for example, a hollow polygonal cylindrical enclosure.

Stiffeners 267 are fixed to the wall plate 254 to provide structural support, as well as, provide elements that can be used for the positioning and orientation of the wall panel 252 during assembly and disassembly of the tank 10. The stiffeners 267 generally comprise a top stiffener 256, vertical stiffeners 258, a bottom stiffener 260, lifting lug stiffeners 262, and lifting lug plates 264. The top stiffener 256 comprises an elongate rectangular tube fixed to the wall plate 254 an offset distance below its top edge and running from one end to the other end of the wall plate 254. The vertical stiffeners 258 comprise elongate rectangular plates fixed at one or more locations along the length of the wall plate 254 and running from the bottom to the top of the wall plate 254. The bottom stiffener 260 comprises an elongate “L” shaped beam fixed to the wall plate 254 near its bottom edge and running parallel thereto from one end to the other end of the wall plate 214. Lifting lug stiffeners 262 comprise rectangular plates fixed to the vertical stiffeners 258 where an aperture is provided through the lifting lug stiffener 224 and the vertical stiffener 218. Lifting lug plates 264 comprise tabs fixed to and extending from the top stiffener 256 and having an aperture therethrough. The apertures in the lifting lug stiffeners 262, vertical stiffeners 258, and lifting lug plates 264 serve as attachment points for hooks or other devices for the positioning and orientation of the lower wall panel 252 during assembly and disassembly of the tank 10. Alternatively, the stiffeners 267 may comprise more or less vertical, horizontal or other stiffeners for providing structural support, as well as, elements that can be used for the positioning and orientation of the lower wall panel 252 during assembly and disassembly of the tank 10.

Female connectors 267 generally comprise a female backbone 268, female inside plates 270, female outside plates 272, horizontal guide plates 276, and locking bar gussets 278, 280. The female backbone 268 comprises a generally rectangular plate fixed to one longitudinal end of the wall plate 254 running from the bottom to the top of the wall plate 254. The female backbone 268 has a thickness selected to permit the male connectors 282 to be received by the female connectors 267. Alternatively, the wall plate 254 may serve as the female backbone 268. The female inside plates 270 comprise generally rectangular plates that are fixed to the inner surface of the female backbone 268 spaced along the length of the female backbone 268, and extend away from the wall plate 254 in a direction parallel to the length thereof. Similarly, the female outside plates 272 comprise generally rectangular plates that are fixed to the outer surface of the female backbone 268 spaced along the length of the female backbone 268, and extend away from the wall plate 254 in a direction parallel to the length thereof. Each female outside plate 272 is positioned on the outside surface of the female backbone 268 so as to oppose and pair with a corresponding female inside plate 270 fixed to the inside surface of the female backbone 268. In addition, each female outside plate 272 and paired female inside plate 270 comprise a set of apertures 271, 273 in alignment with one another that are configured to receive a joint pin 300 (as further described below). Each female connector 267 also comprises locking bar gussets 278, 280 fixed to the outside surface of the female outside plate 272 shouldering one of the apertures 273 in vertical alignment with one another. The locking bar gussets 278, 280 comprise apertures 287 that are aligned with apertures 287 in adjacent locking bar gussets 278, 280 that are configured to receive a locking bar 320. As further described below, the aperture 287 of locking bar gusset 280 comprises an open-ended aperture that extends to the top edge of the gusset 280 such that the handle 324 of the locking bar 320 can pass through the aperture 287 as the bar 322 of the locking bar 320 is inserted through the apertures 287 of the locking bar gussets 278, 280. Further, the top and bottom female connectors 267 also comprise horizontal guide plates 276 fixed to and spanning the bottom of the female inside plate 270 and female outside plate 272 of each top and bottom female connector 267. The horizontal guide plates 276 function to align and guide the male connectors 282 of the wall panel 252 being received by the female connectors 267. For the purpose of this disclosure, each female inside plate 270, corresponding female outside plate 272, the portion of the female backbone 268 therebetween, the locking bar gussets 278, 280, and the horizontal guide plates 276 (as applicable to the top and bottom female connectors 267), will be referred to as a single female connector 267.

Male connectors 282 comprise generally rectangular plates that are fixed to the longitudinal end of the wall plate 254 opposite to the longitudinal end to which the female connectors 267 are fixed, and extending away from the wall plate 254 in a direction parallel to the length thereof. Male connectors 282 are spaced along the length of the end of the wall plate 254 such that for each female connector 267 fixed to the opposite end of the wall plate 254 there is a corresponding male connector 282 in vertical alignment therewith. Each male connector 282 also comprises a set of apertures 283 configured to be in alignment with apertures 271, 273 of a corresponding female connector 267 of an adjacent upper wall panel 252 when received thereby. In this manner, when the male connectors 282 of one lower wall panel 252 are received by the female connectors 267 of another lower wall panel 252, the apertures 271, 273 of each female connector 267 and the apertures 283 of each received male connector 282 will be in alignment such that they are capable of receiving a joint pin 300 therethrough.

Guide plates 266 comprise tabs fixed to and extending from the top stiffener 256 spaced along the length of the top stiffener 256. The guide plates 266, top stiffener 256 and portion of the wall plate 254 extending above the top stiffener 256, define a seat configured to receive and support the base of an upper wall panel 212 therebetween. In this manner, the bottom of the upper wall sub-assembly 210 is coupled to the top of the lower wall sub-assembly 250 through a tongue and groove assembly. In the alternative, the upper wall sub-assembly 210 may be coupled to the lower wall sub-assembly 250 using other suitable coupling mechanisms.

Stacking components 283 facilitate the stacking of lower wall panels 252 upon one another during transportation or storage. In addition, the stacking components 283 function to protect the insulating layer 295 of the lower wall panels 252 from damage that may be otherwise cause by adjacent stacked upper wall panels 252. Stacking components 283 generally comprise stack up gussets 284 fixed near the longitudinal ends of the bottom stiffener 260 and extending in a generally perpendicular direction outwardly from the outer surface of the wall plate 254, and stack up stand offs 286 fixed near the longitudinal ends of the top stiffener 256 and extending in a generally perpendicular direction outwardly from the outer surface of the wall plate 254. In the alternative, other stacking components suitable for facilitating the stacking of lower wall panels 252 may be employed.

An insulating layer 295 is coupled to the outside surface of the wall plate 254. The insulating layer 295 may be comprised of suitable spray foam applied to the outer surface of the wall plate 254. Alternatively, the insulating layer 295 may be coupled to the inner surface of the wall plate 254. In the further alternative, the insulating layer 295 may comprise insulating panels or other insulating materials coupled to the outer and/or inner surface of the wall plate 254.

Referring to FIG. 7, joint pins 300 generally comprise a pin prong 302 and pin handle 314. The pin prong 302 comprises spaced fingers 306 extending from a base 304. The base 304 comprises a top surface 308 spanning between adjacent fingers 306 and a bottom surface 310 opposite the top surface 308. The fingers 306 are sized to be received by and extend through (a) apertures 229, 231 of a female connector 225 and apertures 237 of a male connector 236 of upper wall panel 212 when received by the female connector 225, and (b) apertures 271, 273 of a female connector 267 and apertures 283 of a male connector 282 of lower wall panel 252 when received by the female connector 267. In addition, the fingers 306 comprise bevelled tips to assist in positioning the fingers 306 into apertures 229, 231, 236 and 271, 273, 283. The pin handle 314 is a generally “U” shaped handle fixed to the bottom surface 310 of the base 304 of the pin prong 302 defining a void 316 between the pin handle 314 and bottom surface 310. Alternatively, the joint pin 300 may comprise any number of fingers 306.

Referring to FIG. 8, locking bars 320 generally comprise a bar 322 and a handle 324. The bar 322 comprises a cylindrical rod sized to be received by and extend through (a) apertures 241 of locking bar gussets 232,234 of a female connector 225 of upper wall panel 212 and (b) apertures 287 of locking bar gussets 278, 280 of a female connector 267 of lower wall panel 252. The handle 324 comprises a cylindrical rod fixed to the bar 322 and extending in a generally perpendicular direction therefrom. The handle 324 has a thickness sized to fit between adjacent locking bar gussets 232, 234 and 278, 280.

Referring to FIG. 9, during the assembly of the upper wall sub-assembly 210 and lower wall sub-assembly 250, adjacent wall panels 212, 252 are interconnected by inserting the male connectors 236, 282 into the female connectors 225, 267 such that the apertures 229, 231, 236 and 271, 273, 283 are in alignment. The fingers 306 of a joint pin 300 are then inserted through the apertures 229, 231, 236 and 271, 273, 283, until the top surface 308 of the base 304 of the joint pin 300 contacts the outer surface of the female outside plate 230, 272 of the female connector 225, 267. The bar 322 of the locking bar 320 is inserted into and slid through the apertures 241, 287 of locking bar gussets 232, 234 and 278, 280 and through the void 310 between the bottom surface 310 of the base 304 of the pin prong 302 of the joint pin 300 and the handle 314 of the joint pin 300. In the same motion, the handle 324 of the locking bar 320 is positioned to extend upwards such that it can be slid through the aperture 241, 287 of locking bar gusset 234, 280. Once the handle 324 of the locking bar 320 has been slid through the aperture 241, 287 of locking bar gusset 234, 280, the handle 324 is rotated so that it extends downwards and rests between the locking bar gusset 234, 280 and adjacent locking bar gusset 232, 278. In this manner, the locking bar 320 prevents the joint pin 300 from being withdrawn from the male connector 236, 282 and female connector 225, 267, and the locking bar 320 is prevented from further translational motion without first rotating the handle 324 of the locking bar 320 so that it extends upwards and can translate through the locking bar gusset 234, 280. This mechanism of interconnecting adjacent wall panels 212, 252 of the upper wall sub-assembly 210 and lower wall sub-assembly 250 provides a strong and secure coupling between adjacent wall panels, 212, 252 capable of resisting the high forces typically exerted by fluids contained in the tank 10.

Referring again to FIG. 2, wall braces 340 generally comprise supporting plates configured to extended between and couple to the vertical stiffeners 218, 258 of vertically adjacent wall panels 212, 252 in the assembled tank 10. The wall braces 340 function to restrict relative motion between vertically adjacent wall panels 212, 252 in the assembled tank 10. Alternatively, other forms of wall braces 340 that are suitable to restrict relative motion between vertically adjacent wall panels 212, 252 in the assembled tank 10 can be utilized.

Clamp assembly 360 generally comprises a clamp bar 362, clamp 364 and anti-vibration mount 366. The clamp bar 362 comprises a tube to which the clamp 364 is fixed to the outer surface and the anti-vibration mounts 366 are fixed to the inner surface. The clamp 364 is configured to clamped to the liner 50 to couple the liner 50 to the wall assembly 20. The clamp assembly 360 is configured to mount to the clamp mount 222 of upper wall panel 212.

Floor Assembly

Referring to FIG. 10, the floor assembly 40 functions to insulate fluids contained in the tank 10 from the ground and direct the fluids to the location within the tank 10 where a suction pipe is located for withdrawing the fluid from the tank. The floor assembly 40 generally comprises a plurality of modular floor panels 402 and an insulating layer 404. The floor panels 402 are configured to substantially cover the entire surface area of the ground captured within the interior circumferential boundary of the lower wall sub-assembly 250. The panels 402 are manufactured from overlapping plywood sheets that are glued and screwed together. The plywood sheets are cut into elongate generally rectangular strips that are configured to extend across a strip of the ground within the interior of the lower wall sub-assembly 250. The floor panel(s) 402 crossing the centre of the ground within the interior of the lower wall sub-assembly 250 will have the longest length, spanning the diameter of the interior of the lower wall sub-assembly 250, followed by successively shorter length floor panels 402 the further a floor panel 402 is located from the centre of the interior of the lower wall sub-assembly 250. The ends of the floor panels 402 are shaped to substantially conform to the shape of the interior circumferential boundary of the lower wall sub-assembly 250. Alternatively, the panels 402 may comprise a plurality of rectangular panels for positioning within the interior portion of the floor assembly 30 and plurality of shaped panels configured to generally conform to the shape of the interior circumferential boundary of the assembled lower wall sub-assembly 250 for positioning adjacent to the boundary. In the further alternative, the floor panels 402 may be manufactured from fibreglass, composite fibreglass or any other suitable material. In he further alternative the floor panels 402 may be coupled to one another by Velcro or any other suitable attachment mechanism.

An insulating layer 404 is fixed to the top of the floor panels 402. The insulating layer 404 comprises a plurality of insulating foam panels that are positioned on top of the floor panels 402 such that the elevation of the insulation at the boundary of the interior of the lower wall sub-assembly 250 is higher than the elevation of the insulation at the centre of the interior of the lower wall sub-assembly 250. In this manner, the gradient of the floor assembly 40 will tend to drain fluid within the liner 50 contained by the tank 10 towards the centre of the interior of the lower wall sub-assembly 250 where a suction pipe for withdrawing the fluid from the tank 10 will be located. Further, the gradient of the floor assembly 40 permits the tank 10 to be assembled on surfaces that are not level since fluid the gradient of the floor assembly 40 will compensate for imperfections in the level of the surface and direct the fluid to the location of the suction pipe. Alternatively, where it is desired to locate the suction pipe at another location within the interior of the lower wall sub-assembly 250, the insulating layer 404 can be configured on top of the floor panels 402 such that the gradient of the floor assembly 400 directs the fluid contained in the tank 10 to be directed to that location.

An insulating layer 404 may be fixed to every floor panel 402 or only to a subset of floor panels 402 as is required to provide a desired gradient of the floor assembly 40. For example, in some embodiments, the floor panels 402 in closest proximity to the intended location of the suction pipe have an insulating layer 404 fixed to the floor panels 402 in order to provide an area of minimum elevation that the fluid in the tank 10 will be directed to by the gradient of the floor assembly 40. In addition, a channel may be cut into the insulating layer 404 to receive the suction pipe near the boundary of the interior of the lower wall sub-assembly 250 and direct the suction pipe to a desired location within the interior of the lower wall sub-assembly 250. Alternatively, the insulating layer 404 may be manufactured from other suitable insulating materials.

Roof Assembly

Referring to FIGS. 11A to 11C, the roof assembly 30 functions to cover the top of the tank 10 and thereby prevent wildlife from entering the tank 10 and trap heat within the tank 10. The roof assembly 30 generally comprises roof segments 502, a fastening assembly 508, a lifting assembly 512, a drainage assembly 514, and a support pole assembly 516.

Roof segments 502 comprise two roof halves 502A, 502B each comprising a top portion 504A, 504B and a skirt 506A, 506B. Alternatively, the roof segments 502 may comprise more than two segments. When assembled, the top portion 504 of the roof segments 502 covers the top of the upper wall sub-assembly 200 and the skirt 506 extends down a portion of the exterior surface of the upper wall sub-assembly 200. Optionally, the skirt 506 of the roof assembly 30 may be coupled to the wall assembly 20 by way of a tether or other suitable coupling.

The roof segments 502 are manufactured from a flexible insulating material, such as, for example, vinyl treated with a water proof coating, nylon, plastics or any other suitable material. Alternatively, the roof segments 502 can be manufactured from other suitable materials that can prevent wildlife from entering the tank 10 and trap heat within the tank 10.

The roof segments 502 are divided into two halves in order to facilitate the transportation and assembly of the roof assembly 30. The roof segments 502 are coupled to one another along their interior edges 508 by way of the fastening assembly 510. The fastening assembly 510 comprises Velcro straps and safety buckles that are fixed to the roof segments 502 about the length of their interior edges 508. Alternatively, the fastening assembly 510 may comprise other suitable fastening components capable of fastening the roof segments 502 to one another.

The lifting assembly 512 comprises lifting loops fixed to the top portion 504 of the roof segments 502 about the length of the interior edge 508 of the roof segments 502. The lifting assembly 512 provides a point of attachment that can be coupled to by a hook or other suitable device to position of the roof segments 502 on top of the upper wall sub-assembly 200 and in relative position to one another to facilitate the fastening of the fastening assembly 510. In the alternative, the lifting assembly 512 may comprise other suitable lifting components.

The support pole assembly 516 comprises a pole mounted on top of the liner 50 about the centre of the floor assembly 40 and extending vertically therefrom above the top of the wall assembly 20. The support pole assembly 516 functions to support a portion of the weight of the roof assembly 30 and to direct rain water, snow and other fluids forming on top of the roof assembly 30 to the drainage assembly 514. The support pole assembly 516 may optionally comprise a base positioned on top of the liner 50 and configured to receive the bottom of the pole. The base may comprise a water tank or other suitable base structure. Alternatively, the support pole assembly 516 may comprises a plurality of poles mounted at desired locations about interior of the tank 10.

The drainage assembly 514 functions to drain rain water, snow and other fluids forming on top of the roof assembly 30 into the tank 10. The drainage assembly 514 comprises a plurality of drain apertures through the roof segments 502 located at low points on the roof segments 502 that form due to the natural sag of the roof segments 502 between the support pole assembly 516 and the top of the wall assembly 20. The drainage assembly 514 also comprises a mesh layer over each aperture to prevent wildlife from entering the tank 10 therethrough.

Liner

Referring to FIGS. 1A and 1B, the liner 50 comprises a flexible polyurethane container housed within the interior of the wall assembly 20 and draped over the sides of the wall assembly 20 and coupled thereto by clamp assemblies 360. The liner 50 functions to provide a water proof container for receiving fluid within the tank 10.

Assembly Process

Referring to FIG. 12, one embodiment of a method 600 of assembling the tank 10 is provided. In block 602, the components of the tank 10 are transported to a site where the tank 10 is to be assembled, typically by one or more semi-trailer trucks. In block 604, the components of the tank 10 are offloaded to desired location on the site, typically by a picker truck.

In block 606, a first lower wall panel 252 is located to a desired position and orientation, typically by a picker truck. The first lower wall panel 252 is supported in an upright position by a temporary support assembly, typically comprising removable support beams. In block 608, the next lower wall panel 252 is positioned and oriented next to the first lower wall panel 252 such that the male connectors 282 of either the first lower wall panel 252 or next lower wall panel 252 is received by the female connectors 267 of the other of the first lower wall panel 252 or next lower wall panel 252 in alignment therewith. In block 610, the joint pin 300 is inserted through the aligned female connectors 267 and male connectors 282, and locking bar 400 is inserted to secure the joint pin 300, in the manner described above. In block 612, if the lower wall sub-assembly 250 is completed, the method 600 proceeds to block 614, otherwise, blocks 608 to 612 are repeated for the next lower wall panel 252.

In block 614, a first upper wall panel 212 is located to a desired position and orientation on top of the lower wall sub-assembly 250, typically by a picker truck. As described above, the bottom of the first upper wall panel 212 is received by the seat defined by the guide plates 266, top stiffener 256 and portion of the wall plate 254 extending above the top stiffener 256 of the lower wall panel 252 for which the first upper wall panel 212 is positioned on top of. The first upper wall panel 212 is positioned with respect to its supporting lower wall panel 252 such that the vertical stiffeners 218, 258 of the first upper wall panel 212 and supporting lower wall panel 252 are in horizontal alignment. The first lower wall panel 212 is supported in an upright position by a temporary support assembly, typically comprising removable support beams. In block 616, the next upper wall panel 212 is positioned and oriented next to the first upper wall panel 212 such that the male connectors 236 of either the first upper wall panel 212 or next upper wall panel 212 is received by the female connectors 225 of the other of the first lower wall panel 212 or next lower wall panel 212 in alignment therewith. In addition, similar to the first upper wall panel 212, the next upper wall panel 212 is positioned in the seat provide by a supporting lower wall panel 252. Similar to the first upper wall panel 212, the next upper wall panel 212 is positioned with respect to its supporting lower wall panel 252 such that the vertical stiffeners 218, 258 of the next upper wall panel 212 and supporting lower wall panel 252 are in horizontal alignment.

In block 618, the joint pin 300 is inserted through the aligned female connectors 225 and male connectors 236, and locking bar 400 is inserted to secure the joint pin 300, in the manner described above. In block 620, if the upper wall sub-assembly 210 is completed, the method 600 proceeds to block 622, otherwise, blocks 616 to 620 are repeated for the next upper wall panel 212.

In block 622, the wall braces 340 are attached to selected vertical stiffeners 218, 258 of aligned lower wall panel 252 and upper wall panels 212. In block 624, clamp assemblies 260 are coupled to clamp mounts 222 of upper wall panels 212.

In block 626, the floor panels 402 are set out on the ground within the interior circumferential boundary of the lower wall sub-assembly 250 in their designated locations. In block 628, the insulating layer 404 is fixed to the top of the floor panels 402 such that the elevation of the insulation at the boundary of the interior of the lower wall sub-assembly 250 is higher than the elevation of the insulation at the centre of the interior of the lower wall sub-assembly 250.

In block 630, the liner is positioned inside of the wall assembly 20, draped over the upper edges of the wall assembly 20 and coupled to clamp assemblies 260. In block 632, the suction pipe for withdrawing fluid from the tank 10 and the inlet and outlet pipes used for heating fluid contained in the tank 10 are inserted into the interior of the liner 50 within the wall assembly 20.

In block 634, the support pole assembly 516 is mounted on top of the liner 50 about the centre of the floor assembly 40 and extending vertically therefrom above the top of the wall assembly 20. In block 636, the roof segments 502 are laid out on the ground and are coupled together by the fastening assembly 508. In block 638, the assembled roof segments 502 are positioned on top of the wall assembly 20 and support pole assembly 516 such that the skirt 506 of the roof assembly 30 extends down a portion of the exterior of the wall assembly 20, typically through the use of a picker truck. In 40, optionally, the skirt 506 may be coupled to the wall assembly 20 by way of tethers or other suitable coupling devices.

After the completion of method 600, the tank may be filled with fluid and used in operation.

While particular embodiments of the present invention has been described in the foregoing, it is to be understood that other embodiments are possible within the scope of the invention and are intended to be included herein. It will be clear to any person skilled in the art that modifications of and adjustments to this invention, not shown, are possible without departing from the spirit of the invention as demonstrated through the exemplary embodiment. The invention is therefore to be considered limited solely by the scope of the appended claims. 

1. A fluid storage tank assembly comprising: a wall assembly circumscribing an interior chamber of the tank assembly and providing a thermal insulating layer, the wall assembly comprising two or more wall sub-assemblies removably stacked on top of each other, each wall sub-assembly comprising a plurality of removably interconnected wall panels circumscribing a portion of the interior chamber, the wall assembly configured to house a liner for containing a fluid; a floor assembly bounding a bottom portion of the interior chamber and providing a thermal insulating layer; and a roof assembly bounding a top portion of the interior chamber and providing a thermal insulating layer.
 2. The tank assembly as claimed in claim 1, wherein the floor assembly comprises a surface gradient operable to direct fluids contained in the tank assembly to a desired location on the floor assembly.
 3. The tank assembly as claimed claim 2, wherein the floor assembly comprises: a plurality of floor panels; and an insulating layer fixed to the floor panels and shaped to provide the surface gradient.
 4. The tank assembly as claimed in claim 3, wherein the plurality of floor panels comprise an arrangement of parallel substantially rectangular panels configured to bound the bottom of the interior of the wall assembly, each panel extending across the interior of the wall assembly and having ends shaped to substantially conform with the interior boundary of the wall assembly.
 5. The tank assembly as claimed in claim 3, wherein the plurality of floor panels comprise an arrangement of substantially rectangular panels configured to bound the bottom of the interior of the wall assembly, and wherein panels located adjacent to the interior boundary of the wall assembly shaped to substantially conform with the interior boundary of the wall assembly.
 6. The tank assembly as claimed in claim 3, wherein a portion of the floor panels near the desired location on the floor assembly does not comprise a thermal insulating layer.
 7. The tank assembly as claimed in claim 3, wherein the insulating layer comprises a channel therein, the channel configured to receive a suction pipe near the boundary of the interior of the wall assembly and direct the suction pipe to the desired location on the floor assembly.
 8. The tank assembly as claimed in claim 3, wherein each floor panel is removably coupled to adjacent floor panels.
 9. The tank assembly a claimed in claim 1, wherein each wall panel further comprise an insulating layer fixed thereto.
 10. The tank assembly as claimed in claim 1, wherein each wall panel comprises a plurality of male connectors at one end and a plurality of female connectors at an opposite end, the male connectors configured to be received by and removably coupled to the female connectors of an adjacent wall panel in a wall sub-assembly, the female connectors configured to received by and removably coupled to the male connectors of an adjacent wall panel in the wall sub-assembly.
 11. The tank assembly as claimed in claim 10, wherein: the wall assembly further comprises a plurality of joint pins and locking bars; each male connector comprises one or more apertures configured to receive a joint pin therethrough; each female connector comprises one or more apertures configured to receive a joint pin therethrough, each female connector further comprises a plurality of gussets extending from an exterior surface of the female connector and shouldering one of the apertures therein, each gussets comprising an aperture configured to receive a locking bar therethrough; the apertures of the male connectors and female connectors configured to be in alignment with one another to receive a joint pin therethrough when the male connectors are received by the female connectors; and each locking bar is operable to be received by the apertures of the gussets of a female connector and interact with a joint pin received by a female connector and a male connector received by the female connector to resist the withdrawal of the joint pin therefrom.
 12. The tank assembly as claimed in claims 1, wherein each wall sub-assembly is removably coupled to an adjacent stacked wall sub-assembly by a cooperating tongue and groove assembly.
 13. The tank assembly as claimed in claim 12, wherein: the wall panel of at least one of the removably coupled wall sub-assemblies comprises a bottom stiffener fixed to the wall panel at its bottom edge and running parallel thereto, the bottom stiffener and the portion of wall panel near its bottom edge defining the tongue of the tongue and groove assembly; and the wall panel of at least the other of the removably coupled wall sub-assemblies comprises a top stiffener fixed to the wall panel an offset distance below its top edge and running parallel thereto and a guide plate fixed to the top stiffener and extending vertically therefrom, the top stiffener, the guide plate and the portion of the wall panel within the offset distance defining the groove of the tongue and groove assembly.
 14. The tank assembly as claimed in claims 1, wherein the roof assembly further comprises a plurality of flexible roof segments and a fastening assembly, the fastening assembly operable to couple adjacent roof segments to one another.
 15. The tank assembly as claimed in claim 14, wherein the roof assembly further comprises a support pole assembly comprising one or more poles extending from the bottom of the tank assembly above the top of the wall assembly; the support pole assembly at least partially supporting the roof segments.
 16. The tank assembly as claimed in claim 15, wherein the roof assembly further comprises a drainage assembly comprising a plurality of apertures through the roof segments located at low points on the roof segment formed by a natural sag of the roof segments between the support pole assembly and the top of the wall assembly.
 17. The tank assembly as claimed in claim 14, wherein each roof segment comprises a top portion and a skirt portion, the top portion configured to substantially cover the top of the wall assembly, and the skirt portion configured to extend down a portion of the exterior surface of the wall assembly.
 18. The tank assembly as claimed in claim 17, wherein the skirt portion of each roof segment is removably coupled to the wall assembly.
 19. The tank assembly as claimed in claim 14, wherein the roof assembly further comprises a lifting assembly fixed to the roof segments providing a point of attachment for positioning and orienting the roof segments.
 20. The tank assembly as claimed in claim 16, wherein the drainage assembly further comprises a mesh layer over each aperture in the roof segments. 